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Journal articles on the topic 'Fabrication additive métallique DED'

Author: Grafiati

Published: 13 July 2024

Last updated: 31 July 2025

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1

Park, Seong-Hyun, Kiyoon Yi, Peipei Liu, Gwanghwo Choi, Kyung-Young Jhang, and Hoon Sohn. "In situ and layer-by-layer grain size estimation in additively manufactured metal components using femtosecond laser ultrasonics." Journal of Laser Applications 35, no. 2 (2023): 022002. http://dx.doi.org/10.2351/7.0000938.

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Directed energy deposition (DED) is an additive manufacturing technique wherein a focused thermal energy source and a coaxial powder delivery system are combined for the fabrication of metallic parts. Although rapid progress has been made in DED, the amount of research performed for in situ quality monitoring during fabrication is limited. Grain size monitoring during DED is particularly important because the grain size is directly related to the mechanical strength and stiffness of the final products. In this study, a layer-by-layer grain size estimation technique using femtosecond laser ultr

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Millon, Célia, Arnaud Vanhoye, and Anne-Françoise Obaton. "Ultrasons laser pour la détection de défauts sur pièces de fabrication additive métallique." Photoniques, no. 94 (November 2018): 34–37. http://dx.doi.org/10.1051/photon/20189434.

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La fabrication additive (FA), notamment la FA de pièces métalliques, connait un essor dans les secteurs de pointe comme l’aéronautique ou le médical de par les possibilités accrues en termes de complexité géométrique, de fonctionnalités ou encore de personnalisation des pièces. Cependant, les poudres métalliques et la fusion laser mis en oeuvre dans certains procédés lors de la fabrication conduisent parfois à des défauts, comme par exemple des manques de fusion. Pour réduire les coûts de production engendrés par des pièces finies mais non conformes, la fabrication de ces pièces appelle à déve

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3

Chen, Lequn, Xiling Yao, Youxiang Chew, Fei Weng, Seung Ki Moon, and Guijun Bi. "Data-Driven Adaptive Control for Laser-Based Additive Manufacturing with Automatic Controller Tuning." Applied Sciences 10, no. 22 (2020): 7967. http://dx.doi.org/10.3390/app10227967.

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Closed-loop control is desirable in direct energy deposition (DED) to stabilize the process and improve the fabrication quality. Most existing DED controllers require system identifications by experiments to obtain plant models or layer-dependent adaptive control rules, and such processes are cumbersome and time-consuming. This paper proposes a novel data-driven adaptive control strategy to adjust laser voltage with the melt pool size feedback. A multitasking controller architecture is developed to incorporate an autotuning unit that optimizes controller parameters based on the DED process dat

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4

Saboori, Abdollah, Alberta Aversa, Giulio Marchese, Sara Biamino, Mariangela Lombardi, and Paolo Fino. "Microstructure and Mechanical Properties of AISI 316L Produced by Directed Energy Deposition-Based Additive Manufacturing: A Review." Applied Sciences 10, no. 9 (2020): 3310. http://dx.doi.org/10.3390/app10093310.

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Directed energy deposition (DED) as a metal additive manufacturing technology can be used to produce or repair complex shape parts in a layer-wise process using powder or wire. Thanks to its advantages in the fabrication of net-shape and functionally graded components, DED could attract significant interest in the production of high-value parts for different engineering applications. Nevertheless, the industrialization of this technology remains challenging, mainly because of the lack of knowledge regarding the microstructure and mechanical characteristics of as-built parts, as well as the tru

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Zakerin, Nika, Khashayar Morshed-Behbahani, Donald Paul Bishop, and Ali Nasiri. "Review of Tribological and Wear Behavior of Alloys Fabricated via Directed Energy Deposition Additive Manufacturing." Journal of Manufacturing and Materials Processing 9, no. 6 (2025): 194. https://doi.org/10.3390/jmmp9060194.

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Additive manufacturing (AM) is a rapidly evolving technology that enables the fabrication of complex 3D components across a wide range of materials and applications. Among various AM techniques, direct energy deposition (DED) has gained significant attention for its ability to produce metal and alloy components with moderate geometric complexity while maintaining a high deposition rate. This makes DED particularly suitable for real-world applications, including in-situ repair and restoration of metallic parts. Due to the nature of the DED process, components undergo extreme heating and cooling

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Sidun, Muhammad Irfan Syahmi, and Ismayuzri Ishak. "Bead Characterization for Wire Based Laser Directed Energy Deposition Fabrication Process." Jurnal Teknologi 13, no. 2 (2023): 58–64. http://dx.doi.org/10.35134/jitekin.v13i2.98.

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A three-dimensional, solid object of almost any shape or design can be created using metal additive manufacturing, often known as metal 3D printing. One of the most popular materials utilized in additive manufacturing is metal. The far more complicated procedure of directed energy deposition (DED) is frequently employed to upgrade or repair existing components. DED fabrication process will be able to construct a 3D metal object with consideration of the weld bead characteristics. Without knowing the weld bead characteristics, the mechanical integrity will not hold as the bead size is not suita

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7

Jedlan, Štěpán, Martin Ševeček, Antonín Prantl, Josef Hodek, Pavel Podaný, and Michal Brázda. "Effect of heat-treatment on material properties of L-DED printed austenistic alloy 08CH18N10T for nuclear reactor applications." Acta Polytechnica CTU Proceedings 44 (December 1, 2023): 1–4. http://dx.doi.org/10.14311/app.2023.44.0001.

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This paper deals with the evaluation of material properties of the additively manufactured austenistic alloy 08CH18N10T, which is widely used in the Czech Republic nuclear power plants Temelín and Dukovany and other VVER reactors around the world. For purposes of utilization of additive manufacturing technologies for nuclear core components fabrication, two sets of samples were prepared from horizontally and vertically L-DED printed blocks from 08CH18N10T material. Experiments such as microstructure analysis, porosity and Vickers hardness were then performed on L-DED printed and heat-treated 0

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Ostolaza, Marta, Jon Iñaki Arrizubieta, Aitzol Lamikiz, Soraya Plaza, and Naiara Ortega. "Latest Developments to Manufacture Metal Matrix Composites and Functionally Graded Materials through AM: A State-of-the-Art Review." Materials 16, no. 4 (2023): 1746. http://dx.doi.org/10.3390/ma16041746.

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Multi-material structure fabrication has the potential to address some critical challenges in today’s industrial paradigm. While conventional manufacturing processes cannot deliver multi-material structures in a single operation, additive manufacturing (AM) has come up as an appealing alternative. In particular, laser-directed energy deposition (L-DED) is preferred for multi-material AM. The most relevant applications envisioned for multi-material L-DED are alloy design, metal matrix composites (MMC), and functionally graded materials (FGM). Nonetheless, there are still some issues that need t

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9

He, Wentao, Lida Zhu, Can Liu, and Hongxiao Jiang. "Metal Additive Manufacturing and Molten Pool Dynamic Characterization Monitoring: Advances in Machine Learning for Directed Energy Deposition." Metals 15, no. 2 (2025): 106. https://doi.org/10.3390/met15020106.

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Directed energy deposition (DED) has progressively emerged as a highly promising technology for the rapid, cost-effective, and high-performance fabrication of hard-to-process metal components with shorter production cycles. Recognized as one of the most widely utilized metal additive manufacturing (AM) techniques, DED has found extensive applications in critical industrial sectors such as aerospace and aviation. Despite its potential, challenges such as inconsistent part quality and low process repeatability continue to restrict its broader adoption. The core issue underlying these challenges

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10

Santaolaya, Javier, Jorge Sogorb, Ignacio González-Barba, Antonio Periñán, and Fernando Lasagni. "Development and Optimization of Processing Parameters of 316L Stainless Steel and Inconel 718 by Wire Feed Direct Energy Deposition/Laser Beam (W-DED/LB)." Key Engineering Materials 958 (October 5, 2023): 21–29. http://dx.doi.org/10.4028/p-3mi1yv.

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Within the technologies that make up Additive Manufacturing (AM), one of the ones that have taken the greatest prominence in recent times is DED (Direct Energy Deposition), particularly that of wire feedstock. The W-DED/LB technique has some benefits compared to other AM methods, such as the fabrication of relatively larger parts, repair capabilities of the damaged areas of a component, cladding of different materials on existing parts, and reduced material waste.This study describes the optimisation of processing parameters for the manufacturing stainless steel (SS316L) and Inconel 718 alloys

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Müller, M., C. C. Labisch, L. Gerdt, et al. "Multimaterial direct energy deposition: From three-dimensionally graded components to rapid alloy development for advanced materials." Journal of Laser Applications 35, no. 1 (2023): 012006. http://dx.doi.org/10.2351/7.0000788.

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Laser-based direct energy deposition (L-DED) with blown powder enables the simultaneous or sequential processing of different powder materials within one component and, thus, offers the possibility of additive multimaterial manufacturing. Therefore, the process allows a spatially resolved material allocation and fabrication of sharp or even graded material transitions. Within this contribution, the latest results from two major research fields in multimaterial L-DED—(I) automation and (II) rapid alloy development of high entropy alloys (HEAs) by in situ synthesis—shall be presented. First, an

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Aydogan, Beytullah, and Himanshu Sahasrabudhe. "Enabling Multi-Material Structures of Co-Based Superalloy Using Laser Directed Energy Deposition Additive Manufacturing." Metals 11, no. 11 (2021): 1717. http://dx.doi.org/10.3390/met11111717.

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Cobalt superalloys such as Tribaloys are widely used in environments that involve high temperatures, corrosion, and wear degradation. Additive manufacturing (AM) processes have been investigated for fabricating Co-based alloys due to design flexibility and efficient materials usage. AM processes are suitable for reducing the manufacturing steps and subsequently reducing manufacturing costs by incorporating multi-materials. Laser directed energy deposition (laser DED) is a suitable AM process for fabricating Co-based alloys. T800 is one of the commercially available Tribaloys that is strengthen

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13

Chalicheemalapalli Jayasankar, Deviprasad, Stefan Gnaase, Dennis Lehnert, Artur Walter, Robin Rohling, and Thomas Tröster. "Effect of Substrate Temperature on Bead Track Geometry of 316L in Directed Energy Deposition: Investigation and Regression Modeling." Metals 14, no. 12 (2024): 1353. http://dx.doi.org/10.3390/met14121353.

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The optimization of process parameters in powder Directed Energy Deposition (DED) is essential for achieving consistent, high-quality bead geometries, which directly influence the performance and structural integrity of fabricated components. As a subset of additive manufacturing (AM), the DED process, also referred to as laser metal deposition (LMD), enables precise, layer-by-layer material deposition, making it highly suitable for complex geometries and part repair applications. Critical parameters, such as the laser power, feed rate, powder mass flow, and substrate temperature govern the de

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14

Booysen, Theo-Neal, Tamba Jamiru, Taoreed Adegbola, and Nana Arthur. "Microstructural effects on properties of as-fabricated Inconel 625 with direct energy deposition process." MATEC Web of Conferences 388 (2023): 08001. http://dx.doi.org/10.1051/matecconf/202338808001.

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Three-dimensional printing (3D), also known as metal additive manufacturing (MAM), fabricates parts or components from different feedstocks: wires, powders or sheets. This process differs from traditional manufacturing techniques such as casting, moulding, or subtracting existing materials. In the development and improvement or fabrication of new materials for higher strength and various applications, the type or character of a material is very important as this will ascertain the strength of the finished product. Direct energy technology can be used to fabricate and repair parts or components

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15

Morales, Cindy, Annalisa Fortini, Chiara Soffritti, and Mattia Merlin. "Effect of Post-Fabrication Heat Treatments on the Microstructure of WC-12Co Direct Energy Depositions." Coatings 13, no. 8 (2023): 1459. http://dx.doi.org/10.3390/coatings13081459.

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Laser-Directed Energy Deposition (L-DED) is an additive manufacturing technique that has lately been employed to deposit coatings of cemented carbides, such as WC-Co. During deposition, complex microstructural phenomena usually occur, strongly affecting the microstructural and mechanical behavior of the coatings. Post-fabrication heat treatments (PFHTs) may be applied to homogenize and strengthen the microstructure; nevertheless, to the best of the authors’ knowledge, just a few papers deepened the effect of these treatments on cemented carbides fabricated by additive manufacturing. This work

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16

Dussa, Saikumar, Sameehan S. Joshi, Shashank Sharma, Karri Venkata Mani Krishna, Madhavan Radhakrishnan, and Narendra B. Dahotre. "Additively Manufactured Alnico Permanent Magnet Materials—A Review." Magnetism 4, no. 2 (2024): 125–56. http://dx.doi.org/10.3390/magnetism4020010.

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Additive manufacturing offers manufacturing flexibility for intricate components and also allows for precise control over the microstructure. This review paper explores the current state of the art in additive manufacturing techniques for Alnico permanent magnets, emphasizing the notable advantages and challenges associated with this innovative approach. Both the LPBF and L-DED processes have demonstrated promising results in fabricating Alnico with magnetic properties comparable with conventionally processed samples. The optimization of process parameters successfully reduced porosity and cra

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17

Froes, F. H., and B. Dutta. "The Additive Manufacturing (AM) of Titanium Alloys." Advanced Materials Research 1019 (October 2014): 19–25. http://dx.doi.org/10.4028/www.scientific.net/amr.1019.19.

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High cost is the major reason that there is not more wide-spread use of titanium alloys. Powder Metallurgy (P/M) represents one cost effective approach to fabrication of titanium components and Additive Manufacturing (AM) is an emerging attractive PM Technique . In this paper AM is discussed with the emphasis on the “work horse” titanium alloy Ti-6Al-4V. The various approaches to AM are presented and discussed, followed by some examples of components produced by AM. The microstructures and mechanical properties of Ti-6Al-4V produced by AM are listed and shown to compare very well with cast and

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18

Chandrashekharaiah S. B. "Additive manufacturing of MMCs: challenges and opportunities." World Journal of Advanced Research and Reviews 2, no. 1 (2019): 084–91. https://doi.org/10.30574/wjarr.2019.2.1.0127.

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Additive Manufacturing (AM) of Metal Matrix Composites (MMCs) is an emerging technology that combines the benefits of advanced manufacturing with the superior mechanical properties of composite materials. This innovative approach enables complex geometries, material efficiency, and tailored mechanical performance, making it highly desirable for aerospace, automotive, biomedical, and defense applications. However, several challenges limit its full industrial adoption, including process optimization, material compatibility, and defect formation. This paper provides a comprehensive exploration of

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Mazeeva, Alina, Dmitriy Masaylo, Gleb Konov, and Anatoliy Popovich. "Multi-Metal Additive Manufacturing by Extrusion-Based 3D Printing for Structural Applications: A Review." Metals 14, no. 11 (2024): 1296. http://dx.doi.org/10.3390/met14111296.

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Additive manufacturing (AM) is a rapidly developing technical field that is becoming an irreplaceable tool to fabricate unique complex-shaped parts in aerospace, the automotive industry, medicine, and so on. One of the most promising directions for AM application is the design and production of multi-material components with different types of chemical, structural, and architectural gradients that also promote a breakthrough in bio-inspired approaches. At the moment there are a lot of different AM techniques involving various types of materials. This paper represents a review of extrusion-base

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Çallı, Metin, Emre İsa Albak, and Ferruh Öztürk. "Prediction and Optimization of the Design and Process Parameters of a Hybrid DED Product Using Artificial Intelligence." Applied Sciences 12, no. 10 (2022): 5027. http://dx.doi.org/10.3390/app12105027.

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Directed energy deposition (DED) is an additive manufacturing process used in manufacturing free form geometries, repair applications, coating and surface modification, and fabrication of functionally graded materials. It is a process in which focused thermal energy is used to fuse materials by melting. Thermal effects can cause distortions and defects on the parts during the DED process, therefore they should be evaluated and taken into account during the manufacturing of products. Melting pool control and DED bead geometries should be defined properly as well. In this work, an Artificial Neu

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Aldalur, Eider, Fernando Veiga, Alfredo Suárez, Jon Bilbao, and Aitzol Lamikiz. "Analysis of the Wall Geometry with Different Strategies for High Deposition Wire Arc Additive Manufacturing of Mild Steel." Metals 10, no. 7 (2020): 892. http://dx.doi.org/10.3390/met10070892.

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Additive manufacturing has gained relevance in recent decades as an alternative to the manufacture of metal parts. Among the additive technologies, those that are classified as Directed Energy Deposition (DED) are characterized by their high deposition rate, noticeably, Wire Arc Additive Manufacturing (WAAM). However, having the inability to produce parts with acceptable final surface quality and high geometric precision is to be considered an important disadvantage in this process. In this paper, different torch trajectory strategies (oscillatory motion and overlap) in the fabrication of low

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22

Ali, Nashit, Luca Tomesani, Alessandro Ascari, and Alessandro Fortunato. "Fabrication of Thin Walls with and without Close Loop Control as a Function of Scan Strategy Via Direct Energy Deposition." Lasers in Manufacturing and Materials Processing 9, no. 1 (2022): 81–101. http://dx.doi.org/10.1007/s40516-022-00164-8.

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AbstractDirect Energy Deposition (DED) is a technique used to fabricate metallic parts and is a subcategory of metal additive manufacturing. Despite of its vast advantages over traditional manufacturing the deployment at industrial level is still limited due to underlaying concerns of process stability and repeatability. In-situ monitoring, therefore, is indispensable while depositing via DED. The present experiment is a step towards enhancing our current understanding of the DED when coupled with a closed loop control system to control melt pool width for deposition of thin-walled structures,

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Boillat-Newport, Rachel, Sriram Praneeth Isanaka, and Frank Liou. "Heat Treatment Post-Processing for the Improved Mechanical Properties of Scalmalloy® Processed via Directed Energy Deposition." Crystals 14, no. 8 (2024): 688. http://dx.doi.org/10.3390/cryst14080688.

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As high-strength aluminum alloys present several processability issues with additive manufacturing (AM), Scalmalloy®, an Al-Mg-Sc-Zr-based alloy, has been developed. This alloy is age-hardenable, allowing it to precipitate out a strengthening precipitate phase, Al3(Sc,Zr). The manufacturer recommends a single-stage aging treatment at 325 °C for 4 h; however, the majority of the literature studies utilize a powder bed processing known as selective laser melting (SLM) over powder-fed processing directed energy deposition (DED). This study addresses the lack of information on heat treatments for

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Gudur, Srinath, Suryakumar Simhambhatla, and N. Venkata Reddy. "Enhancing the Shape Complexity in Direct Energy Deposition with Phased Deformation." International Journal of Automation Technology 16, no. 5 (2022): 642–53. http://dx.doi.org/10.20965/ijat.2022.p0642.

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Wire-based direct energy deposition (W-DED) techniques in metal additive manufacturing allow part-fabrication at higher deposition rates and lower costs. Given the lack of any support mechanism, these processes face challenges in fabricating overhanging features. The inherent overhang capability of weld-beads and higher-order kinematics can help realize certain complex geometries. However, significant challenges like non-uniform slicing, constrained deposition-torch accessibility, etc., limit the efficacy of these approaches. The present work describes a deformation-aided deposition process de

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Choi, Young Woon, Seung Woo Paek, Huichan Park, and Sang Won Lee. "A Study on Multi-sensor Data Transformation for Directed Energy Deposition Process." International Journal of Precision Engineering and Manufacturing-Smart Technology 3, no. 2 (2025): 117–24. https://doi.org/10.57062/ijpem-st.2025.00073.

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A Directed Energy Deposition (DED) process is a crucial additive manufacturing (AM) technology that enables metal part fabrication and repair. However, real-time monitoring and quality assessment remain challenging because the molten pool is sensitive to process parameters. This study proposed a sensor data transformation AI model to enhance immersive digital twin-based monitoring of the DED process. A 3D Convolutional Autoencoder was employed to transform vision-based molten pool images into temperature data, eliminating the need for direct temperature measurement. To improve model accuracy,

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Ratnala, Dilipkumar Choudary, Joel Andersson, and Shrikant Joshi. "Development of Functionally Graded Metal-Ceramic Systems by Directed Energy Deposition: A Review." Materials Science Forum 1107 (December 6, 2023): 105–10. http://dx.doi.org/10.4028/p-4ekatd.

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Ceramics and metals are the two vastly explored classes of materials whose individual characteristics and targeted applications differ significantly. Continuous thrust for space exploration and energy generation demands materials with a wide range of properties. To tackle this demand, ceramic-metal combined structures that club heat, wear, and corrosion resistance of ceramics to the high toughness, good strength, and better machinability of metals are desirable. While various processing routes to combine ceramics and metals have been developed through the years, solutions to address problems a

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Pathak, Puskar, Goran Majkic, and Venkat Selvamanickam. "Role of customized scan strategies and dwell time on microstructure and properties of additively manufactured 316L stainless steel." Materials Science in Additive Manufacturing 3, no. 1 (2024): 2676. http://dx.doi.org/10.36922/msam.2676.

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Direct energy deposition (DED)-based additive manufacturing facilitates fabrication of medium-to-large functional parts. This study assesses the role of varying scan strategies and dwell time between each layer to control the cooling rate of 316L stainless steel produced by the laser-engineered net shaping-DED method. Customized print patterns were designed, keeping other optimized print parameters constant to obtain printed parts with better dimensional tolerance. The parts, which were >99% dense, were fabricated in a controlled argon environment. A heterogeneous microstructure consisting

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Jeong, Ho-In, Osama Salem, Dong-Won Jung, Choon-Man Lee, and Jeung-Hoon Lee. "Impact of Conventional and Laser-Assisted Machining on the Microstructure and Mechanical Properties of Ti-Nb-Cr-V-Ni High-Entropy Alloy Fabricated with Directed Energy Deposition." Micromachines 15, no. 12 (2024): 1457. https://doi.org/10.3390/mi15121457.

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The high-entropy alloy (HEA) has recently attracted significant interest due to its novel alloy design concept and exceptional mechanical properties, which may exhibit either a single or multi-phase structure. Specifically, refractory high-entropy alloys (RHEA) composed of titanium, niobium, and nickel-based HEA demonstrate remarkable mechanical properties at elevated temperatures. Additive manufacturing (AM), specifically Direct Energy Deposition (DED), is efficient in fabricating high-entropy alloys (HEA) owing to its fast-cooling rates, which promote uniform microstructures and reduce defec

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Ning, Jinsheng, Lida Zhu, Shuhao Wang, et al. "Printability disparities in heterogeneous material combinations via laser directed energy deposition: a comparative study." International Journal of Extreme Manufacturing 6, no. 2 (2024): 025001. http://dx.doi.org/10.1088/2631-7990/ad172f.

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Abstract Additive manufacturing provides achievability for the fabrication of bimetallic and multi-material structures; however, the material compatibility and bondability directly affect the parts’ formability and final quality. It is essential to understand the underlying printability of different material combinations based on an adapted process. Here, the printability disparities of two common and attractive material combinations (nickel- and iron-based alloys) are evaluated at the macro and micro levels via laser directed energy deposition (DED). The deposition processes were captured usi

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Liu, Chen, Yu Zhan, Hongjian Zhao, Shuo Shang, and Changsheng Liu. "The Effect of Process Parameters on the Temperature and Stress Fields in Directed Energy Deposition Inconel 690 Alloy." Materials 17, no. 6 (2024): 1338. http://dx.doi.org/10.3390/ma17061338.

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Additive manufacturing (AM) technology has the advantages of designability, short process times, high flexibility, etc., making it especially suitable for manufacturing complex high-performance components for high-end industrial systems. However, the intensive temperature gradients caused by the rapid heating and cooling processes of AM can generate high levels of residual stresses, which directly affect the precision and serviceability of the components. Taking Inconel 690 alloy, which is widely used in nuclear power plants, as the research object, a thermo-coupled mechanical model of tempera

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Uralde, Virginia, Alfredo Suarez, Eider Aldalur, Fernando Veiga, and Tomas Ballesteros. "Wall Fabrication by Direct Energy Deposition (DED) Combining Mild Steel (ER70) and Stainless Steel (SS 316L): Microstructure and Mechanical Properties." Materials 15, no. 17 (2022): 5828. http://dx.doi.org/10.3390/ma15175828.

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Direct energy deposition is gaining much visibility in research as one of the most adaptable additive manufacturing technologies for industry due to its ease of application and high deposition rates. The possibility of combining these materials to obtain parts with variable mechanical properties is an important task to be studied. The combination of two types of steel, mild steel ER70-6 and stainless steel SS 316L, for the fabrication of a wall by direct energy deposition was studied for this paper. The separate fabrication of these two materials was studied for the microstructurally flawless

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Dabbaghi, Hediyeh, Nasrin Taheri Andani, Mohammad Pourshams, Mahyar Sojoodi, Behrang Poorganji, and Mohammad Elahinia. "Processability and Material Behavior of NiTi Shape Memory Alloys Using Wire Laser-Directed Energy Deposition (WL-DED)." Journal of Manufacturing and Materials Processing 9, no. 1 (2025): 15. https://doi.org/10.3390/jmmp9010015.

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Utilizing additive manufacturing (AM) techniques with shape memory alloys (SMAs) like NiTi shows great promise for fabricating highly flexible and functionally superior 3D metallic structures. Compared to methods relying on powder feedstocks, wire-based additive manufacturing processes provide a viable alternative, addressing challenges such as chemical composition instability, material availability, higher feedstock costs, and limitations on part size while simplifying process development. This study presented a novel approach by thoroughly assessing the printability of Ni-rich Ni55.94Ti (Wt.

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White, Emma, Emily Rinko, Timothy Prost, et al. "Processing of Alnico Magnets by Additive Manufacturing." Applied Sciences 9, no. 22 (2019): 4843. http://dx.doi.org/10.3390/app9224843.

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Permanent magnets without rare earth (RE) elements, such as alnico, will improve supply stability and potentially decrease permanent magnet cost, especially for traction drive motors and other increased temperature applications. Commercial alnico magnets with the highest energy product are produced by directional solidification (DS) to achieve a <001> columnar grain orientation followed by significant final machining, adding to the high cost. Additive manufacturing (AM) is an effective method to process near net-shape parts with minimal final machining of complex geometries. AM also, has

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Ekengwu, Ignatius Echezona, and Kingsley Izuchukwu Emeruwa. "Metal-Based Additive Manufacturing: Innovations in Methods, Applications, Challenges, and Advancements in Material Science." Material Science Research India 22, no. 1 (2025): 61–75. https://doi.org/10.13005/msri/220105.

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ABSTRACT: Metal-based additive manufacturing (AM) represents a significant advancement in material science, revolutionizing the design, fabrication, and application of metal components. This review examines the material science foundation’s underpinning key AM methods, including Powder Bed Fusion (PBF), Direct Energy Deposition (DED), Binder Jetting, Metal Material Extrusion, and Sheet Lamination. It discusses the material-specific challenges and opportunities these methods offer, particularly in the context of alloy development, powder characteristics, microstructural control, and mechanical

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Andrade, David G., Carlos Zhu, Hélio C. Miranda, and Dulce M. Rodrigues. "Thermal, Microstructural, and Mechanical Analysis of Complex Lattice Structures Produced by Direct Energy Deposition." Materials 17, no. 12 (2024): 2813. http://dx.doi.org/10.3390/ma17122813.

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Lattice structures have gained attention in engineering due to their lightweight properties. However, the complex geometry of lattice structures and the high melting temperature of metals present significant manufacturing challenges for the large-scale fabrication of these structures. Direct Energy Deposition (DED) methods, such as the Wire Arc Additive Manufacturing (WAAM) technique, appear to be an interesting solution for overcoming these limitations. This study provides a detailed analysis of the manufacturing process of carbon steel lattice structures with auxetic geometry. The study incl

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Halder, Rajib, Petrus C. Pistorius, Scott Blazanin, et al. "The Effect of Interlayer Delay on the Heat Accumulation, Microstructures, and Properties in Laser Hot Wire Directed Energy Deposition of Ti-6Al-4V Single-Wall." Materials 17, no. 13 (2024): 3307. http://dx.doi.org/10.3390/ma17133307.

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Laser hot wire directed energy deposition (LHW-DED) is a layer-by-layer additive manufacturing technique that permits the fabrication of large-scale Ti-6Al-4V (Ti64) components with a high deposition rate and has gained traction in the aerospace sector in recent years. However, one of the major challenges in LHW-DED Ti64 is heat accumulation, which affects the part quality, microstructure, and properties of as-built specimens. These issues require a comprehensive understanding of the layerwise heat-accumulation-driven process–structure–property relationship in as-deposited samples. In this stu

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da Silva, Tadeu C., Edwin Sallica-Leva, Emilio Rayón, et al. "Microstructure, Thermal, and Mechanical Behavior of NiTi Shape Memory Alloy Obtained by Micro Wire and Arc Direct Energy Deposition." Journal of Manufacturing and Materials Processing 9, no. 2 (2025): 57. https://doi.org/10.3390/jmmp9020057.

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Additive manufacturing (AM) is revolutionizing the fabrication of metallic components, offering significant potential to compete with or complement traditional casting, forging, and machining processes, and enabling the production of complex functional components. Recent advancements in AM technology have facilitated the processing of shape memory alloys (SMAs) with functional properties comparable to those of conventionally processed alloys. However, the AM of NiTi SMAs remains underexplored due to the extreme complexity of the process, high melting point, and reactivity with oxygen. This stu

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Müller, Christoph, Johanna Müller, Harald Kloft, and Jonas Hensel. "Design of Structural Steel Components According to Manufacturing Possibilities of the Robot-Guided DED-Arc Process." Buildings 12, no. 12 (2022): 2154. http://dx.doi.org/10.3390/buildings12122154.

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Additive manufacturing with the DED-arc process offers limited freedom in terms of the geometric shape of work pieces. The process and fabrication systems restrict the part geometry producible, which must be taken into account during design already. For this reason, a design process was investigated in which geometry generation is based on a self-organizing system. The aim of using a self-organizing system is the possibility to directly control the geometry-defining points. Next to load cases, the design method considers geometric boundary conditions from the production process when generating

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Sato, Naoko, Mitsutaka Matsumoto, Hisato Ogiso, and Harumichi Sato. "Challenges of Remanufacturing Using Powder Bed Fusion Based Additive Manufacturing." International Journal of Automation Technology 16, no. 6 (2022): 773–82. http://dx.doi.org/10.20965/ijat.2022.p0773.

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Remanufacturing is an industrial process of turning used products into products with the same quality as new ones. Of the processes comprising remanufacturing, the repair process poses the greatest challenge. Additive manufacturing (AM) is expected to bring innovation to the repair process of remanufacturing. Although, so far, the directed energy deposition (DED) type AM has been most frequently applied to remanufacturing and only a few studies applied powder bed fusion (PBF) type AM to remanufacturing, PBF demonstrates great potential for application in remanufacturing. This study aims to ass

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Boillat-Newport, Rachel, Sriram Praneeth Isanaka, and Frank Liou. "Impact of Delayed Artificial Aging on Tensile Properties and Microstructural Evolution of Directed Energy Deposited Scalmalloy®." Applied Sciences 15, no. 7 (2025): 3674. https://doi.org/10.3390/app15073674.

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Scalmalloy® is a novel alloy designed to work with the unique processing inherent in additive manufacturing (AM). This alloy is post-processed using a single artificial aging treatment rather than a multistep heat treatment, as often noted in traditional manufacturing processes. Much of the literature details the impact of direct aging treatments around the temperature and time recommended by the manufacturer, 325 °C for 4 h; however, few studies have explored the impact of delayed artificial aging on the resulting mechanical and microstructural behavior. This study explored this missing link

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Nabil, Shadman Tahsin, Cristian Banuelos, Michael E. Madigan, et al. "Microstructure Refinement of Bulk Inconel 718 Parts During Fabrication with EB-PBF Using Scanning Strategies: Transition from Bidirectional-Raster to Stochastic Point-Based Melting." Journal of Manufacturing and Materials Processing 8, no. 6 (2024): 241. http://dx.doi.org/10.3390/jmmp8060241.

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Inconel 718 is a widely popular aerospace superalloy known for its high-temperature performance and resistance to oxidation, creep, and corrosion. Traditional manufacturing methods, like casting and powder metallurgy, face challenges with intricate shapes that can result in porosity and uniformity issues. On the other hand, Additive Manufacturing (AM) techniques such as Powder Bed Fusion (PBF) and Direct Energy Deposition (DED) can allow the creation of intricate single-part components to reduce weight and maintain structural integrity. However, AM parts often exhibit directional solidificatio

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McLain, Braden, Remy Mathenia, Todd Sparks, and Frank Liou. "Machine Vision to Provide Quantitative Analysis of Meltpool Stability for a Coaxial Wire Directed Energy Deposition Process." Materials 17, no. 21 (2024): 5311. http://dx.doi.org/10.3390/ma17215311.

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Wire-based additive manufacturing (AM) is at the forefront of complex metal fabrication because of its scalability for large components, potential for high deposition rates, and ease of use. A common goal of wire directed energy deposition (DED) is preserving a stable process throughout deposition. If too little energy is put into the deposition, the wire will stub into the substrate and begin oscillating, creating turbulence within the meltpool. If too much energy exists, the wire will overheat, causing surface tension to take over and create liquid drips as opposed to a solid bead. This pape

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Noh, Inwoong, Jaehun Jeon, and Sang Won Lee. "A Study on Metallographic and Machining Characteristics of Functionally Graded Material Produced by Directed Energy Deposition." Crystals 13, no. 10 (2023): 1491. http://dx.doi.org/10.3390/cryst13101491.

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Directed energy deposition (DED) stands as a key process in metal additive manufacturing (AM) and offers the unique capability of creating functionally graded materials (FGMs). FGMs have garnered significant interest in high-value industries by advantages such as performance optimization, reducing material defects, and resolving joining issues. However, post-processing remains a crucial step, indicating a need for further research to understand the machinability of FGMs. This paper focuses on the characteristics analysis of fabricating and machining an FGM based on stainless steel 316L (SAE 31

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Buj-Corral, Irene, Aitor Tejo-Otero, and Felip Fenollosa-Artés. "Development of AM Technologies for Metals in the Sector of Medical Implants." Metals 10, no. 5 (2020): 686. http://dx.doi.org/10.3390/met10050686.

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Additive manufacturing (AM) processes have undergone significant progress in recent years, having been implemented in sectors as diverse as automotive, aerospace, electrical component manufacturing, etc. In the medical sector, different devices are printed, such as implants, surgical guides, scaffolds, tissue engineering, etc. Although nowadays some implants are made of plastics or ceramics, metals have been traditionally employed in their manufacture. However, metallic implants obtained by traditional methods such as machining have the drawbacks that they are manufactured in standard sizes, a

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Zhang, Dongqi, Dong Du, Shuai Xue, Junjie Qi, Jiaming Zhang, and Baohua Chang. "Study on Mitigation of Interfacial Intermetallic Compounds by Applying Alternating Magnetic Field in Laser-Directed Energy Deposition of Ti6Al4V/AA2024 Dissimilar Materials." Metals 14, no. 11 (2024): 1250. http://dx.doi.org/10.3390/met14111250.

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Brittle intermetallic compounds (IMCs) at the interface of dissimilar materials can seriously affect the mechanical properties of the dissimilar components. Introducing external assisted fields in the fabrication of dissimilar components is a potential solution to this problem. In this study, an alternating magnetic field (AMF) was introduced for the first time in the additive manufacturing of Ti6Al4V/AA2024 dissimilar alloy components by laser-directed energy deposition (L-DED). The effect of the AMF on the interfacial IMCs’ distribution was studied. The results indicate that the contents of

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Stolidi, Adrien, Anthony Touron, Loïc Toulemonde, Audrey Gardahaut, and Jean-Paul Garandet. "Monitoring en ligne par fluorescence X des procédés de fabrication additive métallique." e-journal of nondestructive testing 28, no. 9 (2023). http://dx.doi.org/10.58286/28476.

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Cette communication présente des résultats de spectrométrie par fluorescence X à dispersion d’énergie (ED-XRF) acquis durant des procédés de fabrication additive métallique. Cette technique de caractérisation sans contact et non-destructive est appliquée à deux techniques de fabrication additive métallique. Le but est de renforcer la maitrise de ces procédés et de répondre à des exigences de contrôle qualité. Deux cas d’études sont abordés, l’un concernant des mesures effectuées sur des échantillons possédant une gradation de la composition chimique de l’alliage, l’autre présentant le monitori

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Lee, Jin-Woo, Soo-Jeong Park, and Yun-Hae Kim. "Numerical prediction of thermal stress–strain behavior on the wire-directed energy deposition additive manufacturing for automotive component." Modern Physics Letters B, April 9, 2022. http://dx.doi.org/10.1142/s0217984922420040.

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Wire-directed energy deposition (wire-DED) is used to create a shape in a layer-by-layer manner by depositing a consumable welding wire, where a welding arc is the source of heat. This technology can be used to fabricate large components with higher deposition rates compared to other 3D metal printing methods. Despite these benefits, the components of wire-DED are affected by heat distortion and residual stress. Therefore, the prediction of deformation before fabrication using wire-DED is essential for determining the range of machining for the final products. In this study, the deformation an

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Schneider, J. A., G. Puerto, E. Walker, et al. "Wire Based Directed Energy Deposition of JBK-75." Metallurgical and Materials Transactions A, February 22, 2024. http://dx.doi.org/10.1007/s11661-024-07306-x.

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AbstractApplications and adoption of metal additive manufacturing (AM) are increasing for fabrication of low volume, complex components with novel materials, as well as replacement parts. While the use of powder bed fusion-based processes have been widely used to build complex components with fine feature resolution, there is a volume limitation. Expanding the application of metal AM will rely on other processes that remove this build size constraint. These processes are referred to as Directed Energy Deposition (DED) and can use either powder or wire feedstock. Wire based DED provides the hig

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Saboori, Abdollah, Alberta Aversa, Giulio Marchese, Sara Biamino, Mariangela Lombardi, and Paolo Fino. "Microstructure and Mechanical Properties of AISI 316L Produced by Directed Energy Deposition-Based Additive Manufacturing: A Review." May 11, 2020. https://doi.org/10.3390/app10093310.

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Directed energy deposition (DED) as a metal additive manufacturing technology can be used to produce or repair complex shape parts in a layer-wise process using powder or wire. Thanks to its advantages in the fabrication of net-shape and functionally graded components, DED could attract significant interest in the production of high-value parts for different engineering applications. Nevertheless, the industrialization of this technology remains challenging, mainly because of the lack of knowledge regarding the microstructure and mechanical characteristics of as-built parts, as well as the tru

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Judd, Kiran, Matthew Register, Kyle Tsaknopoulos, et al. "A Coupled Modeling-Experimental Approach for Predictive Thermodynamic Modeling of Wire-Arc Directed Energy Deposition (DED) in Fe-10Ni and ER120S-1 Steels." JOM, June 18, 2025. https://doi.org/10.1007/s11837-025-07487-9.

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Abstract Wire-arc directed energy deposition (DED) provides a more cost- and energy-efficient solution for the fabrication of large-scale parts compared to conventional manufacturing techniques, such as casting. However, materials fabricated via wire-arc DED can have different properties due to the cyclic heating that occurs during deposition. This study investigates the predicted volume fraction of phases, thermal history, microstructure, and mechanical properties of wire-arc DED-deposited ER120S-1 and Fe-10Ni feedstock wires and compares them to conventionally manufactured wrought high-yield

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